Gasketless high pressure connection

ABSTRACT

A sealing system for a high pressure pump, in which the pump includes a vessel defining a vessel bore and having an end portion, the vessel bore having a first engagement face and defining a central longitudinal axis, and in which the pump further includes a plunger cooperative with the vessel to increase the pressure of a fluid within the bore, includes a seal member at least partially received within the bore and defining a second engagement face. The sealing system further includes a retaining member in operative contact with the seal member to mate the first engagement face with the second engagement face to inhibit fluid leakage from the bore. The first engagement face includes a first contacting surface having a non-linear cross-section. The second engagement face includes a second contacting surface having a non-linear cross-section in contact with the first contacting surface.

RELATED APPLICATION DATA

The present application claims priority under 35 U.S.C. §119 toProvisional Patent Application No. 61/545,236, filed Oct. 10, 2011, thedisclosure of which is hereby incorporated by reference.

BACKGROUND

The present invention relates to a gasketless high pressure connectionfor an ultrahigh pressure fluid pump.

Precision cutting for industrial and commercial purposes is oftenaccomplished through the use of a waterjet system that directs a highspeed stream of water at a material surface to be cut. Waterjet systemspressurize water to about 30,000 psi and convert that pressure to afluid stream traveling at speeds in excess of Mach 2. This high velocitystream, often mixed with an abrasive, is capable of slicing through hardmaterials such as metal and granite with thicknesses of more than afoot.

SUMMARY

The pumps operating within a waterjet system require sealing connectionsable to contain the high pressures generated. Seal gaskets positionedbetween the sealing surfaces in such an environment are typicallyconstructed of a softer material than that of the surrounding componentsand tend to rapidly break down, requiring frequent replacement. Asealing assembly for these purposes should therefore effectively sealthe high pressure side from a low pressure side without prematurefailure or necessitating unreasonable maintenance.

In one embodiment of a sealing system for a high pressure pump, the pumpincludes a vessel defining a vessel bore and having an end portion. Thevessel bore has a first engagement face and defines a centrallongitudinal axis. The pump further includes a plunger cooperative withthe vessel to increase the pressure of a fluid within the bore. Thesealing system includes a seal member at least partially received withinthe bore and defining a second engagement face, and a retaining memberin operative contact with the seal member to mate the first engagementface with the second engagement face to inhibit fluid leakage from thebore. The first engagement face includes a first contacting surfacehaving a non-linear cross-section. The second engagement face includes asecond contacting surface having a non-linear cross-section in contactwith the first contacting surface.

A high pressure pumping system for fluid in excess of 15,000 psi definesa longitudinal axis. A first component includes a first engagement facehaving a first contacting surface with a first non-linear cross-sectionthat is convex. A second component includes a second engagement facehaving a second contacting surface with a second non-linear crosssection that is concave. A retaining member is coupled to one of thefirst component and the second component to sealingly connect the firstengagement face to the second engagement face to inhibit fluid leakagetherebetween.

A high pressure pump for producing fluid pressure in excess of 15,000psi includes a vessel including an end portion having a first engagementface. The vessel includes a vessel bore that defines a centrallongitudinal axis and is in communication with a source of fluid. Aplunger is cooperative with the vessel to increase the pressure of afluid within the bore. A seal member is at least partially receivedwithin the bore and defines a second engagement face. A retaining memberis in operative contact with the seal member and with the vessel to matethe first engagement face with the second engagement face to inhibitfluid leakage from the bore. The first engagement face includes a convexcontacting surface with a variable radius continuously increasing withincreasing distance from the longitudinal axis.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing an abrasive waterjet cuttingsystem.

FIG. 2 is a perspective view of the intensifier pump of the abrasivewaterjet cutting system of FIG. 1.

FIG. 3 is a cross sectional view of the intensifier pump of FIG. 2 takenalong line 3-3.

FIG. 4 is a partial cross sectional view of an end portion of theintensifier pump of FIG. 3.

FIG. 5 is a partial cross sectional view of the end portion of FIG. 4,showing a portion of the seal head engaging the cylindrical vessel.

FIG. 6 is a partial cross sectional view of another embodiment of theend portion of FIG. 4, showing a portion of the seal head engaging thecylindrical vessel.

FIG. 7 is a partial cross sectional view of another embodiment of theend portion of FIG. 4, showing a portion of the seal head engaging thecylindrical vessel.

FIG. 8 is a partial cross sectional view of another embodiment of theend portion of FIG. 4, showing a portion of the seal head engaging thecylindrical vessel.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. And as used herein and in the appendedclaims, the terms “upper”, “lower”, “top”, “bottom”, “front”, “back”,and other directional terms are not intended to require any particularorientation, but are instead used for purposes of description only.

It should be noted that “ultrahigh” or ‘high pressure” as used hereinrefers to fluid pressure in excess of 15,000 psi. One of ordinary skillin the art will realize that unique problems occur at these highpressures. Thus, solutions common to lower pressure pumps are notnecessarily applicable to systems operating at pressures in excess of30,000 psi and in fact can produce results contrary to those seen in lowpressure operation.

FIG. 1 illustrates an abrasive waterjet cutting system 10 for cutting aparticular material with a high pressure stream of water mixed withabrasive. The cutting system 10 includes a cutting table 20 with amaterial supporting surface 22 and a cutting head assembly 30 thatincludes a cutting head 40. The cutting head assembly 30 is controlledthrough a computer 50 and is functionally movable via the arms 24, 26 ina manner known to those of skill in the art to provide cutting at anyrequired operable location on the surface 22. A pumping system 60generates high pressure fluid, typically water, for the cutting processand provides that water through a high pressure tube (not shown) to thecutting head assembly 30. A feed system 70 supplies an abrasivematerial, such as garnet, that is combined with the water stream at thecutting head 40. An abrasive removal system 80 filters the wastewaterproduced in the process to recover the abrasive for further use. Thewastewater can be disposed of through a drain or recycled to minimizeoverall water usage.

FIGS. 2 and 3 illustrate a double acting high pressure pump 100 of thepumping system 60. As is well known to those of skill in the art, thistype of pump, also referred to as an intensifier pump, includes a powercylinder 110 defining a hydraulic fluid chamber 114. A double-sidedpiston 118 coupled to opposing plungers 122 alternates back and forthwithin the chamber 114 in response to pressurized hydraulic fluiddirected into and out of the chamber 114. One or more proximity switches126 detect the piston 118, and when detected, send a signal to acontroller such as a PLC to switch a 4-way valve on the hydraulic pump,thus directing hydraulic oil to the other side of the piston 118 throughthe ports 128 at the bottom of the power cylinder 110. Thepiston/plunger assembly acts as a pressure multiplier to increase thepressure of a fluid, such as water, drawn into the bores 130 of twoopposing cylindrical vessels 134. The vessels 134 are coupled to thepower cylinder 110 through hydraulic cylinder heads 138. A pump head 140is disposed on the ends 142, 144 of each cylindrical vessel 134. Thepump head 140 includes a seal head 146 partially disposed inside an endcap 150. Each end 142, 144 is substantially identical and capable ofdelivering high pressure fluid to the waterjet cutting system.

As shown in FIGS. 3 and 4, the seal head assembly 146 includes an inletcheck valve 154 configured to allow low pressure water to enter the bore130 as the plunger 122 is retracted, and an outlet check valve 158 todirect high pressure fluid to the outlet 162 as the plunger 122 advanceswithin the bore 130. Referring to FIG. 4, the end cap 150 in theillustrated embodiment includes female threads 166 for mating with malethreads 170 on an outer surface of a hollow stud 174. In otherembodiments, the end cap 150 can be secured to the hollow stud 174 withan alternative removable connection. For example, tie rods (not shown)may extend the length of the vessel 134 and couple the hydrauliccylinder head 138 to the end cap 150. A plurality of jack bolts 180threaded into apertures 184 of the end cap 150 each include end faces190 that engage the shoulder 194 of the seal head 146 and provide acompressive force to press the seal head 146 into sealing relationshipwith an end portion 200 of the cylindrical vessel 134. As will befurther described below, the seal head 146 includes an engagement face208 proximate an engagement face 212 of the end portion 200 of thecylindrical vessel 134. The secured cylindrical vessel 134, seal head146, and end cap 150 are all concentric with a longitudinal axis 215through the center of the bore 130.

Referring to FIG. 5, the engagement face 208 includes a generally curvedcontacting surface 216. The curved contacting surface 216 in theillustrated embodiment is concave and has a radius R₁ of approximately0.5″ (17.8 mm), with other radii being possible. In the illustratedconstruction, the surface 216 is defined by a continuous circular curvethat extends the full length of the surface 208, with other curves suchas ellipses, ovals, variable radius curves and the like also beingpossible.

The engagement face 212 includes a substantially linear surface 218 anda blend radius 220 formed between the linear surface 218 and the bore130. Thus, the engagement face 212 is defined in part by the linearsurface 218 and the convex blend radius 220. The blend radius 220 has aradius R₂ of about 0.08″ (2.0 mm) in preferred constructions, withlarger and smaller radii being possible.

The engagement of the concave surface 216 and the blend radius 220provides for a wider seal area than would be achieved if the concavesurface 216 were linear. During operation, the cylinder expands radiallywhich can allow the seal head 146 and the concave surface 216 to moveinward slightly relative to the blend radius 220. During this cyclicprocess, the convex blend radius 220 can rock on the surface 216 suchthat the amount of sliding between the surfaces is reduced. Thereduction in sliding can reduce the likelihood of surface damage,thereby improving the life of the components. The engagement of surfaces216 and 220, when forcibly exerted against each other, exhibits avariable contact angle as they form a pressure-tight seal. The contactangle when the pieces are first mated provides a somewhat shallowcontact angle α with respect to the longitudinal axis 215 that allowsthe seal head 146 to be wedged into the bore 130 of cylinder 134, thusquickly forming a pressure-tight seal with relatively low jack boltforce. As jack bolts 180 are tightened further to exert the properpreload on the joint, the contact angle α changes such that the wedgingaction on the bore 130 of the cylinder 134 is reduced, which slows theintroduction of additional tensile circumferential stresses in the bore,and the contact loading of the seal head 146 on the end of the cylinder134 becomes more axial.

In other constructions, the engagement face 212 includes a convex curvedsurface 224 that extends along at least a portion of the engagement face212 and may or may not blend into a linear surface, as shown in FIG. 6.The surface 224 can be defined by a simple curve such as a circle,ellipse, oval, or the like. Alternatively, the surface 224 is defined bya complex curve, which defines a radius that varies as a function of thedistance from the longitudinal axis 215. The radius of the surface 224can vary continuously from a point having a designated radius R₃ toanother point having a designated radius R₄, or can varynon-continuously from R₃ to R₄. Specifically, the radius of the surface224 can vary continuously such that an infinite number of radii existbetween R₃ and R₄. Alternatively, the radius of the surface 224 can varynon-continuously such that a discrete number of distinct radii (e.g.,one, two, three, etc.) exist between R₃ and R₄, and in someconstructions the surface 224 may be limited to a discrete number ofdistinct radii linearly connected. In the construction of FIG. 6, thecurve radius R₃ is smallest near the axis, for example, approximately0.060″ (1.5 mm), and increases as the distance from the axis increases.As illustrated, the radius along the surface 224 smoothly transitionsfrom R₃ to a larger radius R₄ that ranges from approximately ¼″ (6.4 mm)to approximately ⅜″ (9.5 mm). In addition, the concave contactingsurface 216 in such an embodiment can have a radius R₁ ranging fromapproximately ⅓″ (8.5 mm) to approximately ½″ (12.7 mm). The concavesurface 216 can be similarly arranged such that it can be defined by asimple curve or by a complex curve that can vary continuously ornon-continuously from R₅ to R₁ in the same manner as previouslydescribed for R₃ and R₄.

In another embodiment, the engagement face 208 includes a generallyconvex curved surface 228 that extends the full length of the surface208. Referring to FIG. 7, the convex curved surface 228 is shownproximate the linear surface 218 and the blend radius 220 of theengagement face 212 of the construction illustrated in FIG. 5. In thisconstruction, the curved surface 228 contacts the blend radius 220 toform a seal therebetween. In alternative constructions, the linearsurface 218 and the blend radius 220 are replaced with a convex curvedsurface, to include any of the aforementioned surfaces 224 of FIG. 6.

The engagement of the convex surface 228 and the blend radius 220 (orcurved surface) provides for a narrower seal area than would be achievedif the convex surface 228 were linear. The narrower seal increases thecontact pressure per unit of length when compared to other designs.During operation, the cylinder expands radially, which can allow theseal head 146 and the convex surface 228 to move inward slightlyrelative to the blend radius 220. During this cyclic process, the convexblend radius 220 can rock on the surface 228 such that the amount ofsliding between the surfaces is reduced. The reduction in sliding canreduce the likelihood of surface damage, thereby improving the life ofthe components.

Referring to FIG. 8, another construction includes a seal formed betweenan engagement face 212 defined by a continuous concave curved surface232 and the previously identified convex curved surface 228.

Rather than define the surface 232 with a simple curve such as a circle,ellipse, oval, or the like, the surface 232 is defined by a complexcurve. Specifically, the complex curve defines a radius that varies as afunction of the distance from the longitudinal axis 215. In theillustrated construction, the curve radius is largest near the axis andcontinuously decreases as the distance from the axis increases. Thus,the radius of the curve at a point 236 of the surface 232 is greaterthan the radius of the curve at a point 240.

The construction of FIG. 8 provides benefits similar to those describedfor the construction of FIG. 5. In addition, the use of a variableradius curve or spiral to define the surface 232 improves the sealing ofthe joint. As the seal head 146 is assembled into the cylinder 134 awedging action occurs. The wedging action tends to widen the opening atthe end of the cylinder and is a function of the contact angle α betweenthe surfaces. As the angle gets smaller, the wedging action increases.However, the arrangement of FIG. 8 is such that as the seal head 146moves further into the cylinder 134, the contact angle α increasesslightly, thereby reducing the wedging action as the forces on the sealhead 146 are increased. The reduction in wedging can produce a jointthat provides an adequate seal with less force than would be requiredwith another arrangement.

In other constructions, other curves or combinations of curves could beemployed to form the surfaces of the engagement faces 208, 212. Forexample, ovals, ellipses, other conic sections, etc. could be used aloneor in combination to define the engagement faces 208, 212. In stillother constructions, other complicated or compound curves could beemployed for the surfaces of the engagement faces 208, 212. It shouldalso be noted that the examples illustrated herein could be combined orchanged such that aspects of one illustrated construction could beapplied to other constructions illustrated or described herein.

When urged together by the fastening of the end cap 150 to the hollowstud 174 and the action of the jack bolts 180, the aforementionedsurfaces of the engagement faces 208, 212 illustrated in FIGS. 5-8engage each other at a point of contact 250, the tangent line to whichforms a contact angle α with respect to the longitudinal axis 215 (alsoillustrated locally to the point of contact 250 in FIGS. 5-8). In someconstructions, the contact angle α ranges from approximately 30° toapproximately 60°. In one construction, the contact angle α can be about37°. In another construction, the contact angle α can be about 45°. Instill another construction, the contact angle α can be about 55°.

In operation, the end cap 150 is fastened to the hollow stud 174 toproperly align and provide a first amount of compressive force betweenthe seal head 146 and the end portion 200 of the cylindrical vessel 134.In the case of the construction of FIGS. 3 and 4, the end cap 150 isfastened to the hollow stud 174 which is anchored in the hydrauliccylinder head 138. The jack bolts 180 are rotated to engage the endfaces 190 with the shoulder 194 of the seal head assembly 146 until adesired final amount of compressive force is obtained. When the jackbolts 180 are rotated, the hollow stud 174 is placed in tension and thecylindrical vessel 134 is placed in compression due to the axial load.During rotation of the jack bolts 180, the end faces 190 push the sealhead 146 and the engagement faces 208, 212 together. The engagementfaces 208, 212 interface at the point of contact 250 as previouslydescribed to form a seal that inhibits unwanted flow leakage from thebore 130 throughout the operational pressure fluctuations of the pumpingcycle. In other designs, the hollow stud 174 and the cylindrical vessel134 are combined into one piece and another tensioning method such astie rods are employed to provide the necessary compression between thecylindrical vessel 134 and the seal head 146. In still another design,the end cap 150 is fastened directly to the cylindrical vessel 134 usingmating female and male threads, without the need for the hollow stud174.

It has been unexpectedly determined that the seal engagementconfigurations illustrated and described result in a more effective sealbetween the seal head 146 and the cylindrical vessel 134 than identifiedin previous engagement configurations having alternative geometries. Asan example, the point of contact 250 of the configurations of FIGS. 5-8is in closer proximity to the longitudinal axis 215 than in previousconfigurations. The high pressure fluid being sealed therefore acts on asmaller surface area of the seal head 146, resulting in a lower forcetending to separate the seal head from the cylinder 134. For this andother reasons, the engagement of the seal head 146 and the cylindricalvessel 134, as illustrated in any of FIGS. 5-8 and further describedherein, has been found to provide a satisfactory seal connection at alower required value of compressive force while concurrently reducingthe incidence of galling and spalling between the contacting surfaces.The reduced galling and spalling increases the re-sealability of thecomponents, thereby increasing the life of the components.

In all of the aforementioned embodiments, it is to be understood thatall operational sealing contact of the cylinder 134 with the seal head146 occurs between two curved surfaces, as described herein.

Various features and advantages of the invention are set forth in thefollowing claims.

I claim:
 1. A sealing system for a high pressure pump, the pump having avessel defining a vessel bore and having an end portion, the vessel borehaving a first engagement face and defining a central longitudinal axis,the pump further including a plunger cooperative with the vessel toincrease the pressure of a fluid within the bore, the sealing systemcomprising: a seal member at least partially received within the boreand defining a second engagement face; and a retaining member inoperative contact with the seal member to mate the first engagement facewith the second engagement face to inhibit fluid leakage from the bore,wherein the first engagement face includes a first contacting surfacehaving a non-linear cross-section that is convex or concave, and whereinthe second engagement face includes a second contacting surface having anon-linear cross-section that is the other of convex or concave incontact with the first contacting surface, wherein the non-linearcross-section of the first contacting surface is concave and thenon-linear cross-section of the second contacting surface is convex, andwherein the non-linear cross-section of the second contacting surfaceincludes a first radius and a second radius different from the firstradius, and wherein the radius of the non-linear cross-section of thesecond contacting surface between the first radius and the second radiusis continuously variable.
 2. The sealing system of claim 1, wherein thefirst radius is disposed nearer the longitudinal axis than the secondradius, and further wherein the first radius is smaller than the secondradius.
 3. The sealing system of claim 1, wherein the first contactingsurface and the second contacting surface contact at an initial contactpoint and wherein a tangent of the first contacting surface at theinitial contact point is angled between 30 degrees and 60 degrees withrespect to the longitudinal axis.
 4. A sealing system for a highpressure pump, the pump having a vessel defining a vessel bore andhaving an end portion, the vessel bore having a first engagement faceand defining a central longitudinal axis, the pump further including aplunger cooperative with the vessel to increase the pressure of a fluidwithin the bore, the sealing system comprising: a seal member at leastpartially received within the bore and defining a second engagementface; and a retaining member in operative contact with the seal memberto mate the first engagement face with the second engagement face toinhibit fluid leakage from the bore, wherein the first engagement faceincludes a first contacting surface having a non-linear cross-sectionthat is convex or concave, and wherein the second engagement faceincludes a second contacting surface having a non-linear cross-sectionthat is the other of convex or concave in contact with the firstcontacting surface, wherein the non-linear cross-section of the firstcontacting surface is concave and the non-linear cross-section of thesecond contacting surface is convex, and wherein the non-linearcross-section of the first contacting surface includes an innermostportion having a first radius and an outermost portion having a secondradius different from the first radius, and wherein the radius betweenthe innermost portion and the outermost portion is continuously variablebetween the first radius and the second radius.
 5. A high pressurepumping system for fluid in excess of 15,000 psi, the pumping systemdefining a longitudinal axis and comprising: a first component includinga first engagement face having a first contacting surface with a firstnon-linear cross-section that is convex; a second component including asecond engagement face having a second contacting surface with a secondnon-linear cross section that is concave; and a retaining member coupledto one of the first component and the second component to sealinglyconnect the first engagement face to the second engagement face toinhibit fluid leakage therebetween, wherein the first non-linearcross-section includes an innermost portion having a first radius and anoutermost portion having a second radius different from the firstradius, and wherein the radius between the innermost portion and theoutermost portion is continuously variable between the first radius andthe second radius.
 6. The pumping system of claim 5, wherein the firstradius is smaller than the second radius.
 7. The pumping system of claim5, wherein the second non-linear cross-section includes a first concavecross-section at an innermost portion of the second contacting surfacehaving a third radius and a second concave cross-section adjacent thefirst concave cross-section and having a fourth radius that is differentthan the third radius.
 8. The pumping system of claim 7, wherein thethird radius is smaller than the fourth radius.
 9. The pumping system ofclaim 5, wherein the second non-linear cross-section includes aninnermost portion having a third radius and an outermost portion havinga fourth radius different from the third radius, and wherein the radiusbetween the innermost portion and the outermost portion is continuouslyvariable between the third radius and the fourth radius.
 10. The pumpingsystem of claim 5, wherein the first engagement face and the secondengagement face contact at an initial contact point and wherein atangent of the first engagement face at the initial contact pointbetween 30 degrees and 60 degrees with respect to the longitudinal axis.11. The pumping system of claim 5, wherein the first component includesa longitudinal bore sized to receive a plunger.
 12. A high pressure pumpfor producing fluid pressure in excess of 15,000 psi, the pumpcomprising: a vessel including an end portion having a first engagementface, the vessel including a vessel bore that defines a centrallongitudinal axis and is in communication with a source of fluid; aplunger cooperative with the vessel to increase the pressure of a fluidwithin the bore; a seal member at least partially received within thebore and defining a second engagement face; and a retaining member inoperative contact with the seal member and with the vessel to mate thefirst engagement face with the second engagement face to inhibit fluidleakage from the bore, wherein the first engagement face includes aconvex contacting surface with a variable radius continuously increasingwith increasing distance from the longitudinal axis.
 13. The highpressure pump of claim 12, wherein the convex contacting surfaceincludes a first convex cross-section having a first radius and a secondconvex cross-section adjacent the first convex cross-section and havinga second radius that is different than the first radius, wherein thefirst radius is smaller than the second radius.
 14. The high pressurepump of claim 12, wherein the second engagement face includes a concavecontacting surface with a variable radius continuously increasing withincreasing distance from the longitudinal axis, and wherein the concavecontacting surface includes a first concave cross-section having a thirdradius and a second concave cross-section adjacent the first concavecross-section and having a fourth radius that is different than thethird radius.
 15. The high pressure pump of claim 14, wherein the thirdradius is smaller than the fourth radius.
 16. The high pressure pump ofclaim 14, wherein the first engagement face and the second engagementface contact at an initial contact point and wherein a tangent of thefirst engagement face at the initial contact point between 30 degreesand 60 with respect to the longitudinal axis.
 17. The high pressure pumpof claim 14, wherein the first engagement face and the second engagementface contact at an initial contact point and wherein a tangent of thefirst engagement face at the initial contact point is angled at 55degrees with respect to the longitudinal axis.